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Old 06-01-2005, 07:03 PM   #1
robdogg OP
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LC4 C/S Sprocket Bolt Failure

A fellow LC4 owner I know had his front sprocket fly off on him on a ride on Sunday.

Appearntly the head of the retaining bolt head sheared off - the sprocket and chain jammed up at 50 mph and he slid about 70 ft or so on the pavement (rider unhurt thankfully) and after getting the chain unstuck they noticed one of the sprockets teeth was broken off.

His bike is a 2001 model. I have read in the service manual that on 2003 models they went from the bolt to a nut.

I was considering taking a couple of sprockets along for an adventure ride I am going on and swap them out for the road/dirt sections; but not if it presents a risk of failure.

I don't know the whole story; maybe the sprocket was changed and under/over torqued (which was my first thought); but just wondering if anyone here has heard of this occuring.

(cross posted on KTMTalk btw)
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Old 06-01-2005, 07:17 PM   #2
Mack
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I'd think a new bolt with each chain replacement, loc-tite and proper torquing, and you shouldn't have any worries.

http://www.ADVRider.com/forums/showthread.php?t=78775
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Old 06-01-2005, 07:49 PM   #3
ktmnate
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that sucks. I now have 18k on the 3rd chain and still the original bolt. Now you got me skeered. Hell I got put that on the list with the bearing.
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Old 06-01-2005, 08:09 PM   #4
meat popsicle
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some cut holes in the CS cover and put some paint dabs on there so they can easily keep tabs on the setup. others pay fitty bones for the blingbling touratech Al cover.

i may cut some holes
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Old 06-01-2005, 08:58 PM   #5
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Without knowing the exact history of the bike, it is hard to know if it failed prematurely or it was abused at some point. But enough people have had trouble with this bolt that where there's smoke, there's probably fire. And KTM did ditch the bolt and go with a nut late in the design life of the bike which probably means they felt the bolt design was weak.

The bolt on my 2000 has been in/out a few times without problems under my stewardship and the bike's log shows the PO did it a handful of times also. I do religiously clean the threads, use locktite, and torque to slightly under spec. So far, so good. I think if you're careful, you should be Okay.

This idea of swapping sprockets on the side of the road has always seemed crazy to me. Even in the comfort of my shop with a bike lift, it is a royal PITA to loosen the chain, take off the cover, take the guard out, fish the new sprocket out of there, and fish the new sprocket back in, while handling a stiff, filthy, greasy chain. You'd really have to be sensitive to gearing changes to make this worth doing on a regular basis. And the wear/tear on the bolt seals the deal for me - I'll stick to a 17-tooth front, enjoy the reasonable revs on the highway, and slip the clutch a few times in the tight sections.

- Mark
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Old 06-01-2005, 10:33 PM   #6
Esteban
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I think the bolt is fine as long as you do not over tighten and stress it. It is easy to put a big old cheater bar on this little bolt and snap it right off. It is just as easy to nearly snap it off and then have it fail while running.

Loctite and an easy hand when tightening will insure long life. Probably a new bolt now and then is a good idea too. Guess I will have to buy a new one soon to be safe.

14,000 miles with many CS sprocket swaps and still on the original bolt.

Steve
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Old 06-02-2005, 12:07 PM   #7
Anderssonni
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I bought lc4 640 2000 with about 5000 kms a month ago and when I was inspecting bike before purchasing it I found a real loose counter shaft sprocket bolt. I replaced original with "normal" bolt with equal size. I'm quite a sure that previous owner had not touched that bolt at all.

Antti
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Old 06-02-2005, 12:21 PM   #8
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Quote:
Originally Posted by meat popsicle
some cut holes in the CS cover and put some paint dabs on there so they can easily keep tabs on the setup. others pay fitty bones for the blingbling touratech Al cover.

i may cut some holes
The only problem with the paint trick in this app is the big washer (the one with the rubber cushion ring on it) has a tendancy to turn. The shoulder is a bit thicker than the washer, so it will turn a bit over time.


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Old 06-02-2005, 12:26 PM   #9
robdogg OP
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Quote:
Originally Posted by markjenn
This idea of swapping sprockets on the side of the road has always seemed crazy to me. Even in the comfort of my shop with a bike lift, it is a royal PITA to loosen the chain, take off the cover, take the guard out, fish the new sprocket out of there, and fish the new sprocket back in, while handling a stiff, filthy, greasy chain. You'd really have to be sensitive to gearing changes to make this worth doing on a regular basis. And the wear/tear on the bolt seals the deal for me - I'll stick to a 17-tooth front, enjoy the reasonable revs on the highway, and slip the clutch a few times in the tight sections.

- Mark
Your right; doing it along side a road would be crazy

But the reason I am considering it is because the first part of our ride is all street; 500 miles or so; then the next 950 miles or thereabouts will be almost all dirt; then a few hundred street miles back from Walla Walla to Seattle; We have access to a garage down in Grants Pass with air tools so it's not a problem; and going from a 17 to a 15 is quite a noticable difference (it is to me at least)
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Old 06-02-2005, 12:37 PM   #10
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pretty sure i have an extra set of the hardware someplace right creepy?
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Old 06-02-2005, 12:42 PM   #11
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Quote:
Originally Posted by Loadedagain
pretty sure i have an extra set of the hardware someplace right creepy?
Huh? You mean those wern't gifts? Geez, I guess I better take 'em back off.
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Old 06-02-2005, 12:43 PM   #12
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Quote:
Originally Posted by creeper
Huh? You mean those wern't gifts? Geez, I guess I better take 'em back off.
apparently i no longer have a spare set.
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Old 06-02-2005, 12:44 PM   #13
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ok.... now i'm fuckin angry. creepy you sunofav=bitch.... i cant even type i;m so angered.... you owe me $4 you thieving bastige.


















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Old 06-02-2005, 12:45 PM   #14
creeper
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Quote:
Originally Posted by Loadedagain
apparently i no longer have a spare set.
So, I suppose you're going to tell me next that Walther thing I got isn't a miniature slide hammer?
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Old 06-02-2005, 12:48 PM   #15
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Originally Posted by Loadedagain
ok.... now i'm fuckin angry. creepy you sunofav=bitch.... i cant even type i;m so angered.... you owe me $4 you thieving bastige.

What is that Canukian? 17 cents or so?... You flamin' tranny you, you can't type when you're not angry.
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